Apparatus and method for resonance modulation of firearm discharge gases

ABSTRACT

An apparatus and methods for regulating firearm discharge gases are disclosed. The apparatus may include a muzzle booster having a main body and an orifice including an inner surface. A first baffle may be positioned in the orifice, a second baffle may be positioned against the first baffle. The second baffle may be secured to the inner surface. A distal end cap may be secured to the second baffle. The distal end cap may further include a distal bore. One or more expansion modules may be removably secured to the muzzle booster with a quick connect disconnect fitting. The expansion modules may include modular suppressors for various operational requirements.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/741,590 filed on Oct. 5, 2018. U.S. Provisional Application No. 62/741,590 is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The invention generally relates to firearms. More particularly, the invention relates to a muzzle booster for an autoloading firearm, as well as expansion module suppressors for the muzzle booster.

BACKGROUND

Firearms may be operated by energy that is released from the firing of an ammunition cartridge. More particularly, detonation of a propellant within an ammunition cartridge may release energy that is transformed into mechanical work to induce a firearm's cycle of operation (feeding, chambering, locking, firing, unlocking, extracting, ejecting, cocking). For instance, a gas system for an autoloading rifle may include a pressure impulse-based system which is driven by a gas port. The gas port may be connected via a gas tube to a bolt carrier group. After the unlocking phase of the cycle of operation, the gas tube interface to the bolt carrier group may begin to move in the direction of extraction, and the interface between the gas tube and the bolt carrier may separate. At this point, energy transferred from pressurized exhaust gases within the gas system may be transformed into potential energy within an energy storage system, such as a buffer spring. Potential energy stored in the buffer spring then may be released to initiate another cycle of operation. The amount of energy that is transferred to the projectile and the stored energy that is available for inducing another cycle of operation may affect firearm operation. Accordingly, a need exists for systems and methods which may efficiently utilize energy released during a firearm's cycle of operation.

SUMMARY

Hence, the present invention is generally directed toward an apparatus and method for regulation of firearm discharge gases. In an exemplary embodiment, a muzzle booster and a modular sound suppressor are disclosed. The disclosed embodiments may regulate firearm discharge gases to increase sound signature suppression of a host firearm, decrease flash signature of a host firearm, reduce recoil to a shooter from a host firearm, or increase the accuracy of a host firearm. The disclosed embodiments may fit together to form a tool that may be used to service the muzzle booster. Also, a quick connection and disconnection fitting is disclosed which may further facilitate proper runout alignment of the muzzle booster, expansion module(s), and endcaps following repeated breakdown and reassembly.

DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which form part of this specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:

FIG. 1 is a perspective view of an exemplary embodiment of a muzzle booster mounted on the barrel of a firearm;

FIG. 2 shows a perspective view of the muzzle booster and barrel of FIG. 1;

FIG. 3 shows a partial exploded view of the muzzle booster and barrel of FIG. 2;

FIG. 4 is a partial sectional view of an exemplary interface connecting the muzzle booster and barrel of FIG. 3:

FIG. 5 is a partial sectional view of another exemplary interface connecting the muzzle booster and barrel of FIG. 3:

FIG. 6 is a sectional view of the muzzle booster of FIG. 2 along line 6-6;

FIG. 7 is an exploded view of the muzzle booster of FIG. 2;

FIG. 8 shows a perspective view of the main body of FIG. 7;

FIG. 9 is a sectional view of the main body of FIG. 8 along line 9-9;

FIG. 10 is a perspective view of the blast baffle of FIG. 7;

FIG. 11 is a sectional view of the blast baffle of FIG. 10 along line 11-11;

FIG. 12 is a perspective view of the pressure modulation baffle of FIG. 7;

FIG. 13 is a sectional view of the pressure modulation baffle of FIG. 12 along line 13-13;

FIG. 14 is a perspective view of the distal end cap of FIG. 7;

FIG. 15 is a sectional view of the distal end cap of FIG. 14 along line 15-15;

FIG. 16 shows a perspective view of the spring housing of FIG. 7;

FIG. 17 is a sectional view of the spring housing of FIG. 16 along line 17-17;

FIG. 18 is perspective view of the spring encapsulator of FIG. 7;

FIG. 19 is another perspective view of the spring encapsulator of FIG. 18;

FIG. 20 is an elevation view of the distal end of the muzzle booster of FIG. 2;

FIG. 21 is a perspective view of an exemplary embodiment of a module suppressor deployed on the muzzle booster of FIG. 1;

FIG. 22 is a partial exploded view of FIG. 21 showing an exemplary embodiment of mating quick connect components for deploying the module suppressor on the muzzle booster;

FIG. 23 is a partial section view of FIG. 21 showing the module suppressor deployed on the muzzle booster;

FIG. 24 is a sectional view of the module suppressor deployed on the muzzle booster of FIG. 23 along line 24-24;

FIG. 25 is a partial perspective view of an exemplary housing for a module accessory which may be deployed on the muzzle booster of FIG. 1;

FIG. 26 is a sectional view of the exemplary housing of FIG. 25 along line 26-26;

FIG. 27 is a perspective view of the module suppressor of FIG. 21;

FIG. 28 is a partially exploded view of the module suppressor of FIG. 27;

FIG. 29 is an exploded view of the module suppressor core of FIG. 28;

FIG. 30 is a sectional view of the module suppressor of FIG. 27 along line 30-30;

FIG. 31 is a perspective view of the blast baffle of FIG. 29;

FIG. 32 is a sectional view of the blast baffle of FIG. 31 along line 32-32;

FIG. 33 is a perspective view of the distal end cap of FIG. 29;

FIG. 34 is another perspective view of the distal end cap of FIG. 29;

FIG. 35 is a sectional view of the distal end cap of FIG. 34 along line 35-35;

FIG. 36 is a perspective view of another exemplary module suppressor;

FIG. 37 is an exploded view of the module suppressor of FIG. 36;

FIG. 38 is a sectional view of the module suppressor of FIG. 36 along line 38-38;

FIG. 39 is a detailed view of the module suppressor of FIG. 38;

FIG. 40 is a perspective view of the proximal end cap of FIG. 37;

FIG. 41 is a sectional view of the proximal end cap of FIG. 40 along line 41-41;

FIG. 42 is a perspective view of the blast baffle of FIG. 37;

FIG. 43 is a sectional view of the blast baffle of FIG. 40 along line 43-43;

FIG. 44 is a perspective view of the distal end cap of FIG. 37;

FIG. 45 is another perspective view of the distal end cap of FIG. 37;

FIG. 46 is a sectional view of the distal end cap of FIG. 45 along line 46-46;

FIG. 47 is a perspective view of another exemplary module suppressor;

FIG. 48 is an exploded view of the module suppressor of FIG. 47;

FIG. 49 is a sectional view of the module suppressor of FIG. 47 along line 49-49;

FIG. 50 is a perspective view of the proximal end cap of FIG. 48;

FIG. 51 is a sectional view of the proximal end cap of FIG. 50 along line 51-51;

FIG. 52 is a perspective view of a baffle of FIG. 48;

FIG. 53 is a sectional view of the baffle of FIG. 52 along line 53-53;

FIG. 54 is a perspective view of the distal end cap of FIG. 48;

FIG. 55 is another perspective view of the distal end cap of FIG. 48;

FIG. 56 is a sectional view of the distal end cap of FIG. 54 along line 56-56;

FIG. 57 is a perspective view of yet another exemplary module suppressor;

FIG. 58 is a partially exploded view of the module suppressor of FIG. 57;

FIG. 59 is an exploded view of the module suppressor core of FIG. 58;

FIG. 60 is a sectional view of the module suppressor of FIG. 57 along line 60-60;

FIG. 61 is a perspective view of the blast baffle of FIG. 59;

FIG. 62 is a sectional view of the blast baffle of FIG. 61 along line 61-61;

FIG. 63 is a perspective view of a pressure modulation baffle of FIG. 59;

FIG. 64 is a sectional view of the baffle of FIG. 63 along line 64-64;

FIG. 65 is a perspective view of the distal end cap of FIG. 59;

FIG. 66 is another perspective view of the distal end cap of FIG. 59;

FIG. 67 is a sectional view of the distal end cap of FIG. 65 along line 67-67;

FIG. 68 is a perspective view of another exemplary module suppressor;

FIG. 69 is an exploded view of the module suppressor of FIG. 68;

FIG. 70 is a sectional view of the module suppressor of FIG. 68 along line 70-70;

FIG. 71 is a perspective view of the monocore device of FIG. 69;

FIG. 72 is another perspective view of the monocore device of FIG. 69;

FIG. 73 is a vertical cross-sectional view of monocore device of FIG. 72;

FIG. 74 is a horizontal cross-sectional view of a baffle of FIG. 73;

FIG. 75 is an elevation view of the proximal end of the monocore device of FIG. 72; and

FIG. 76 is an elevation view of the distal end of the monocore device of FIG. 72.

DESCRIPTION

FIG. 1 presents an illustrative firearm 10 which includes an exemplary muzzle booster 12 operatively associated with the barrel 14. The firearm may be an autoloading firearm. Generally, the muzzle booster 12 may be secured to the barrel of the firearm to affect operation of the firearm. For instance, the muzzle booster 12 may be used to increase sound signature suppression of the firearm, decrease flash signature of the firearm, reduce recoil to a shooter from the firearm, or increase the accuracy of the firearm. Additionally, the exemplary muzzle booster 12 may be used to increase cyclic rate of the firearm. Preferably, the muzzle booster may pass a pressure wave of ammunition cartridge discharge gases across an internal baffle array to the modulate the pressure wave and resonance of the pressure wave to increase the cyclic rate of the firearm.

As shown in FIG. 2, the proximal end 16 of the muzzle booster may be connected to the barrel 14 of the firearm. The muzzle booster may convey ammunition cartridge discharge gases through the main body 18 of the muzzle booster to the discharge port (or bore) 20. A flash suppression device 22 may be positioned next to the discharge port. In this embodiment, three distal pointing tines 24 may be oriented radially about the discharge port for flash signature reduction, however, other flash suppression structures or devices may be used in other embodiments. Yet, in other embodiments the muzzle booster may not include a flash suppression structure.

Additionally, the muzzle booster 12 preferably may include a quick connection and disconnection fitting 26 at the distal end. The quick connection and disconnection fitting(s) may include a locking profile 36. The locking profile may include one or more receptacles for releasably securing a mating fitting. The locking profile may provide one or more attachment sites for connecting and locking an expansion module to the muzzle booster. Preferably, the locking profile and expansion module may be configured and dimensioned to provide repeatable and reliable circular runout indexing such that alignment of the muzzle booster and expansion module relative to the bore of the host firearm is maintained during firing despite repeated mounting and unmounting of the expansion module.

Further still, the muzzle booster may include a spring loaded sleeve 30 that prevents fouling of the fitting(s) from environmental debris when not in service. A flange 32 may be located on the main body near the proximal end of the sleeve. Preferably, a spring (see e.g., FIG. 6) 34 may be disposed around the main body 18 next to the flange 32 and below the sleeve 30. The sleeve 30 may be translated over the flange 32 (against the spring force(s)) to provide access to the quick connection and disconnection fitting(s).

As shown in FIG. 3, the muzzle booster 12 may be pinned, or pinned and welded, to the barrel 14. More particularly, the proximal end 16 of the main body may be sized to securely receive the muzzle 38 and a distal segment 40 the barrel. Referring to FIGS. 3, 4, 5 and 6, the proximal end 16 of the main body surrounding an opening for receiving the barrel may possess, a flat, smooth face. The proximal end of the main body may form a right angle with the side-wall of the opening. This may allow the distal segment of the barrel 40 to seat securely in the opening of the main body, which may facilitate an alignment of the muzzle booster and the bore 54. Further, the main body may block movement of the barrel.

Referring to FIG. 3 and FIG. 4, a positive connection between the muzzle booster 12 and the barrel 14 may be implemented by two sets of barrel fixation holes 46 in the main body, along with corresponding pins 48. The two sets of barrel fixation holes in the main body may be pre-drilled or may be drilled after the muzzle booster is seated on the barrel. Preferably, the two sets of barrel fixation holes may be perpendicular to each other and the bore. For instance, as shown in FIG. 2, the main body 18 may include a first group 50 of four barrel fixation holes 46 aligned in one direction that is perpendicular to the passage; whereas, a second group 52 of two barrel fixation holes 26 may be aligned in another direction that is perpendicular to both the passage of the main body and the first group of barrel fixation holes. In this manner, the distal segment of the barrel 40 may be fixed and interlocked with the main body 18.

Referring to FIG. 5, a positive connection between the muzzle booster 12 and the barrel 14 may be implemented by mating screw threads 58, 60. For example, the passage of the main body 18 adjacent the proximal end 16 may include a screw thread 58, and the distal segment of the barrel may include a mating screw thread 60. The muzzle booster body 18 may be interlocked with the barrel 14 by advancing the distal segment of the barrel 40 into the passage 56 until the distal segment 40 of the barrel is fully seated. Further, the main body 18 may be fixed to the barrel 14 by a barrel fixation hole 40 and pin 48 (not shown).

Referring to FIG. 6 and FIG. 7, the muzzle booster 12 may include a spring encapsulator 32, a spring 34, a spring housing, a main body 18, a blast baffle 62, a pressure modulation baffle, and a distal endcap 66. Generally, the muzzle booster 12 may include a firearm discharge gas regulator, as well as a quick connect and disconnect fitting 26. In the exemplary embodiment, the main body 4 may house a discharge gas regulator and quick connect and disconnect. A complementary quick connect/disconnect fitting for mating with the muzzle booster may be part of an accessory expansion module 72 (see e.g., FIGS. 22, 25, 26, 30, 38, 41, 51, 60 and 70).

Referring to FIG. 8, the muzzle booster 12 may include a main body 18. The main body 18 may include a proximal end 16, a distal end 28, and an orifice 56 extending from the proximal end to the distal end. The orifice further may include an inner surface. Also, the inner surface 74 of the orifice may have a central axis 76 and a cross section through the central axis.

Referring to FIG. 9, the inner section 74 may include a first segment 80 abutting the proximal end, the first segment 80 comprising a first side wall 82, the first sidewall bounding a first volume 84 and defining a first inner diameter d₁ perpendicular to the central axis. The inner section 74 may include a second segment 86 proximate the first segment 80, the second segment comprising a second side wall 88 bounding a second volume 90 and defining a second inner diameter d₂, the second inner diameter d₂ being greater than the first inner diameter d₁. The inner surface may include a third segment 92. The third segment 92 may include a third side wall 94 bounding a third volume 96 and defining a third inner diameter d₃ perpendicular to the central axis. The third inner diameter d₃ may be greater than the second inner diameter d₂. The third segment 92 further may include a first transverse surface 98 abutting the third side wall 92 and the second side wall 88. The first transverse surface 98 may form a first seat for the first intermediate segment 100 of the first baffle. (see e.g., FIG. 10).

The inner surface 74 of the orifice 56 further may include a fourth segment 104. The fourth segment 104 may include a fourth side wall 104 bounding a fourth volume 106 and defining a fourth inner diameter d₄ perpendicular to the central axis. The fourth inner diameter d₄ may be greater than the third inner diameter d₃. The fourth side wall 104 may include a first screw thread 108 for securing the second baffle 64 to the main body. (see e.g., FIG. 6)

The inner surface 74 of the orifice 56 further may include a fifth segment 110. The fifth segment 110 may include a fifth side wall bounding a fifth volume 114 and defining a fifth inner diameter d₅ perpendicular to the central axis. The fifth inner diameter d₅ may be greater than the fourth inner diameter d₄. The fifth side wall 112 may cooperate with a feature (e.g., a circular wall 116 on a mating complementary quick connect/disconnect fitting 70) of an accessory expansion module 72 to seal flow of ammunition cartridge discharge gases exiting the muzzle booster 12 and entering the expansion module 72. (see e.g., FIGS. 22 and 23).

As shown in FIG. 8 and FIG. 9, the main body 18 may include an outer surface 118 extending from the proximal end to the distal end 28. The outer surface 118 may include a first band 120 between the proximal end and the distal end, the first band 120 may include a first outer surface segment 122. The first outer surface segment 122 may have a first outer dimension d₆. The first outer surface may include a screw thread 124. (see e.g., FIG. 8). Also, the outer surface 118 further may include a thread relief 126 and a taper thread stop 128 adjacent to the first band.

The outer surface 118 of the main body further may include a second band 130 adjacent to the distal end 88. The second band 120 may include a second outer surface segment 132. The second outer surface segment may have a second outer dimension d₇. Additionally, the second outer surface segment 132 may include a locking profile 134. The locking profile may include a plurality of lug paths 136 disposed radially about the second band 130. Each of the plurality of lug paths 136 may include a first receptacle 138 open to the distal end 28, and a second receptacle 140 adjacent to the first receptacle. The second receptacle 140 further may include a first portion 142 connected to the first receptacle 138, and a second portion 144 separated from the first receptacle 138 and the distal end 28.

Referring to FIG. 9, the outer surface 118 may include a third band 146 adjacent to the second band 130. The third band 146 may include a third outer surface segment 148, which includes a third outer dimension d₈. The third outer dimension d₈ may be less than the second outer dimension d₇. The third band 146 may serve as a spring guide for the spring 34 and as a support for the interior annular ring 150 (see e.g., FIG. 7) as the sleeve 30 translates in the proximal and distal directions.

Referring to FIG. 6, the second sidewall 88 and the first baffle 62 may bound a first chamber 152. The first chamber may possess a first chamber volume 154. Also, the interior space bounded by the second baffle with the distal end cap may bound a second chamber 156. The second chamber may possess a second chamber volume 158. The second chamber volume divided by the first chamber volume may define a chamber ratio. In FIG. 6, the chamber ratio preferably may be between 0.850 and 1.150. In an illustrative example, the chamber ratio may be approximately 0.9.

Referring to FIG. 7, the blast baffle 62 may include an exterior cone 160 and a pair of interior cones 162, 164. The exterior cone 160 may include a double radius curve of specific shape. The positioning of the origin of each radii which trace the external portion of the cone 160 may change based on parameters of the firearm system. These parameters may include the specific caliber of ammunition and the firearm configuration. The interior cones 162, 164 may be, in part, concentric to the outer surface of the exterior cone 160 in the “rear portion” of the baffle 62. Also, the blast baffle 62 may include a stopping surface 100. The stopping surface 100 may be the seating surface for the blast baffle 62 when the blast baffle is positioned in the main body 18. (see e.g., FIG. 6).

Referring to FIG. 11, the blast baffle may include a first central axis 166 and a first cross section 168 through the first central axis 166. The blast baffle may include a first leading end 170, a first trailing end 172 spaced from the first leading end along the first central axis, and a first passage 174 extending from the first leading end 170 to the first trailing end 172. The first passage 174 may be bound by a first interior surface 176. The first interior surface 176 further may include a first leading aperture 178 at the first leading end 170, a first trailing aperture 180 at the first trailing end 172. Also, the first interior surface 176 may include an inner aperture 182 at the distal end of the pressure modulation surface (i.e., the effective inner aperture adjacent to the trailing end). The first leading aperture, the first trailing aperture and the first inner aperture may have inner diameters d₉, d₁₀, and d₁₁, respectively. In the illustrative example, values for the first leading aperture diameter, the first trailing aperture diameter, and the effective inner aperture diameter may be substantially equal to 0.350 inches, and 1.020 inches, respectively. Moreover, the first interior surface 176 further may include a first interior compound curve 184 adjacent to the first leading end 170.

In this context, a compound curve may exhibit a curve ratio. More particularly, the curve ratio may be defined as the radius of the trailing curve divided by the radius of the leading curve. For instance, in FIG. 11, the first interior compound curve 184 may include a first leading curve 186 having a first leading curve radius (R₁) and a first trailing curve 188 having a first trailing curve radius (R₂). In the exemplary embodiment, the first leading curve 186 may be convex with respect to the first central axis 166, and the first trailing curve 188 may be concave with respect to the first central axis 166. Moreover, the first leading curve radius (R₁) may range from approximately 1.1 inches to approximately 1.5 inches, and the first trailing curve radius (R₂) may range from approximately 0.2 inches to approximately 0.4 inches. Indeed, the first leading curve radius (R₁) may preferably range from approximately 1.134 inches to approximately 1.534 inches, and the first trailing curve radius (R₂) may range from approximately 0.292 inches to approximately 0.396. More preferably, the first leading curve radius (R₁) may range from approximately 1.339 inches to approximately 1.329 inches, and the first trailing curve radius (R₂) may range from approximately 0.339 inches to approximately 0.349 inches. In one illustrative example, the first leading curve radius (R₁) may be substantially equal to 1.334 inches, and the first trailing curve radius (R₂) may be substantially equal to 0.344 inches. Accordingly, the first curve ratio may range from approximately 0.190 to approximately 0.349. More preferably, the first curve ratio may be range from approximately 0.253 to approximately 0.263, and most preferably the first curve ratio may be approximately 0.258.

Also, the compound curve may exhibit an inflection point ratio. More particularly, the inflection point ratio may be defined as the trailing inflection point length divided by leading inflection point length. For instance, the first interior compound curve 84 may include a first leading inflection point 140 interposed between the first leading curve 186 and the first trailing curve 188. The first leading inflection point 190 may be being spaced from the leading end 170 along the first central axis 166 by a first leading inflection point length l₁. In the illustrative example, the first leading inflection point length may be substantially equal to 0.641 inches. Further, the first interior compound curve 184 may include a first trailing inflection point 192. The first trailing inflection point may be spaced from the leading end 170 along the first central axis 166 by a first trailing inflection point length l₂. In the illustrative example, the first trailing inflection point length may be substantially equal to 0.850 inches, and thus the inflection point ratio (IPR) of the first interior compound curve 184 may be approximately 1.326.

Further still, the blast baffle may include a first exterior surface 194 extending from the first leading end 170 to the first trailing end 172. The first exterior surface 194 may include a first exterior compound curve 196 proximate to the first leading end 170. The first exterior surface 194 further may include a first trailing linear segment 198 extending from the first trailing end 172 toward the first exterior compound curve 196, as well as an intermediate segment 100 interposed between the first exterior compound curve 196 and the first trailing linear surface 198.

Additionally, the first exterior compound curve 196 may include a first exterior leading curve 200 having a first exterior leading curve radius (R₃). The first exterior leading curve 200 may be convex with respect to the first central axis 160. Also, the first exterior leading curve 200 may include a first exterior trailing curve having a first exterior trailing curve radius (R₄). In the exemplary embodiment, the first exterior compound curve 196 may be convex with respect to the first central axis 200, and the first exterior trailing curve 202 may be convex with respect to the central axis 166. Moreover, the first exterior leading curve radius (R₃) may range from approximately 1.0 inches to approximately 1.5 inches, and the first exterior trailing curve radius (R₄) may range from approximately 0.1 inches to approximately 0.2 inches. Indeed, in the illustrative example, the first exterior leading curve radius (R₃) may preferably range from approximately 1.091 inches to approximately 1.477 inches, and the first exterior trailing curve radius (R₄) may range from approximately 0.106 inches to approximately 0.144. More preferably, the first exterior leading curve radius (R₃) may range from approximately 1.279 inches to approximately 1.289 inches, and the first exterior trailing curve radius (R₄) may range from approximately 0.120 inches to approximately 0.130 inches. In the illustrative example, the first exterior leading curve radius (R₃) may be substantially equal to 1.284 inches, and the first trailing curve radius (R₄) may be substantially equal to 0.125 inches. Accordingly, the first exterior curve ratio may range from approximately 0.072 to approximately 0.132. More preferably, the first exterior curve ratio may be range from approximately 0.093 to approximately 0.102, and most preferably the first exterior curve ratio may be approximately 0.097.

As shown in FIG. 11, the first exterior compound curve 196 further may include a first exterior leading inflection point 204 interposed between the first exterior leading curve 200 and the first exterior trailing curve 202. The first exterior leading inflection point 204 may be spaced from the leading end 170 along the first central axis 166 by a first exterior leading inflection point length l₃. In the illustrative example, the first exterior leading inflection point length may be substantially equal to 0.545 inches. Further, the first exterior compound curve 196 further may include a first exterior trailing inflection point 206 interposed between the first exterior trailing curve 202 and the first intermediate segment 100. The first exterior trailing inflection point 206 may be spaced from the leading end 170 along the first central axis 166 by a first exterior trailing inflection point length l₄. In the illustrative example, the first exterior trailing inflection point length may be substantially equal to 0.600 inches, and thus the inflection point ratio of the first exterior compound curve 196 may be approximately 1.101.

Referring to FIG. 6, the pressure modulation baffle 64 may include an inner and outer surface of a cone, with a bore distal to its length to allow for unimpeded passing of a projectile (e.g., a bullet). The pressure modulation baffle 64 may be configured and dimensioned to modulate a pressure wave of exhaust gases exiting the barrel that were generated from the detonation of an ammunition cartridge in the chamber of the firearm. Further, the pressure modulation baffle may modulate the resonance of the pressure wave in conjunction with the blast baffle 62 and the distal endcap 66.

Referring to FIGS. 7 and 12, the exterior of the cone 208 of the pressure modulation baffle 64 may be a specific angle relative to the bore of the firearm barrel and the intended specific cartridge of the host firearm. The angle and length of the “rear most” portion of the cone 208—in conjunction with the respective features of the blast baffle 62—may provide a modulation of exhaust gas flow that is conducive to the reduction of the sound signature generated by a gunshot of the host firearm.

As shown in FIG. 6, the muzzle booster 12 may include a second baffle 64 positioned against the first trailing aperture 180 of the first baffle 62. Referring to FIG. 13, the second baffle 62 may include a second central axis 210 and a second cross section 212. The second cross section 212 may include a second leading end 214 and a second trailing end 216 spaced from the second leading end along the second central axis. A second passage 218 may extend from the second leading end 214 to the second trailing end 216. The second passage 218 may be bound by a second interior surface 220. The second interior surface 220 may include a second leading aperture 222 at the second leading end 214, and a second trailing aperture 224 at the second trailing end 216. The second interior surface 220 further may include a second leading linear segment 226 adjacent to the second leading end 214, the second leading linear segment 226 being positioned transverse to the second central axis 210 such that the second leading linear segment 226 is disposed at an acute angle (ΘB2) with respect to the second central axis. Generally, the acute angle (ΘB2) may range from approximately 15 degrees to 45 degrees. In the illustrative example, the acute angle may be approximately 32 degrees.

The second interior surface 220 further may include a second curve 228 adjoining the second leading linear segment 226, a second trailing linear segment 230 adjacent to the second curve 228, and a second intermediate segment 232 adjacent to the second curve 228 and the second trailing linear segment 230. The second trailing linear segment 230 may include a screw thread 234. The screw thread 234 may be configured and dimensioned to mate with a screw thread 236 on the distal endcap. (see e.g., FIG. 7). The second intermediate segment 232 may be spaced from the second leading end 214 along the second central axis 210 by a second intermediate segment length l₅. In the illustrative example, the second intermediate segment length l₅ may be substantially equal to 0.752 inches.

The second interior surface 220 further may include a second interior inflection point 238 interposed between the second leading linear segment 226 and the second curve 228. The second interior inflection point 238 may be spaced from the second leading end 214 along the second central axis 210 by a second interior inflection point length l₆. In the illustrative example, the second interior inflection point length l₆ may be substantially equal to 0.602 inches.

Referring to FIG. 12, the second baffle further comprises an second exterior surface 240 extending from the second leading end 214 to the second trailing end 216, the second exterior surface 240 may include a second screw thread 247, the second screw thread may be configured and dimensioned to mate with the screw thread 108 for securing the second baffle 64 to the main body. (see e.g., FIGS. 6, 8, and 9)

Referring to FIG. 13, the pressure modulation baffle 64 further may include a stopping surface 244, an axial radius R₅, and a chamfer 246 about the outermost distal edge of the cone 208. The stopping surface 42 may be a thread relief The axial radius R₅ may be designed and configured to function as a part of the discharge pressure resonance modulation system. In the illustrative example, the axial radius may be approximately 0.300 inches. Similarly, the chamfer 246 may participate in the modulation of exhaust gases and sound signature resonance.

Referring to FIG. 6, the distal endcap 66 may include an inner and outer surface, and a central bore 20 that is concentric to the bore 54 of the host firearm, and an integrated flash hider 22. As shown in FIG. 15, the bore (or aperture) 20 of the distal endcap 66 may be configured and dimensioned to provide for the unimpeded passing of a projectile. The diameter of the bore 20 may be a specific diameter relative to the bullet diameter. Also, a curve 248 may be part of the discharge pressure and resonance modulation design. More particularly, the shape of the curve 248 may be configured to contribute to the modulation efficiency of the muzzle booster 12. The curve 248 may be a double radius curve.

As shown in FIG. 6, the distal end cap 66 may be positioned in the second passage 218. The distal end cap 26 may include a cavity 250 and a discharge port (or bore) exiting the cavity. Referring to FIGS. 14 and 15, the distal end cap 66 may include a third central axis 254 and a third cross section 254. The third cross section 254 may include a third leading end 256 and a third trailing end 210 spaced from the third leading end 258 along the third central axis 252. A cavity wall 210 may extend into the distal end cap from the third leading end 250. The cavity wall may include a third curve 248. The third curve 248 may be concave with respect to the third leading end 256. The third curve 248 may include a third radius (R₆). The discharge port (or bore) 20 may be aligned with the third central axis 252 and may extend from the cavity wall 260 to the third trailing end. The third curve 248 may define an arc which subtends an angle (Θ_(C6)). In the illustrative example, the third curve 248 defines an arc which may subtend an angle of approximately 68 degrees, and the third radius (R₆) may be approximately 0.4 inches. A flash signature reduction device 22 may be positioned adjacent to the discharge port (or bore) 20. Additionally, in the illustrative example, the diameter of the bore (DB) may be 0.30 inches, the diameter of the blast baffle d₉ may be approximately 0.35 inches, the diameter of the pressure modulation baffle d₁₂ may be approximately 0.375 inches, and the diameter of the distal bore (DE) may be approximately 0.40 inches. Also, the spacing between the blast baffle and the pressure modulation baffle may be approximately 0.701 inches.

Referring to FIG. 9, main body 18 may include a void 90 forward of the barrel muzzle. The void 90 may possess a specific volume and specific configuration to decompress exhaust gases exiting the host firearm to a specific pressure before the exhaust gases reach the blast baffle 62. The specific volume and specific configuration of the void 90 may be based on the caliber and pressure of exhaust gases generated by the host firearm.

A surface 98 may be situated next to the void 90. Referring to FIG. 10, a stopping surface 100 on the blast baffle 62 may be configured and dimensioned to seat against the stopping surface 98. As shown in FIG. 6, the stopping surface 100 may block rearward movement of the blast baffle 62. The stopping surface 98, therefore, may hold the blast baffle 62 in place in terms of moving rearward during use as well as during assembly of the muzzle booster 12. Thus, the main body 18 may include a segment 92 for housing a part of the blast baffle 62.

Referring to FIG. 9, the main body 18 further may include another segment 102 for mounting the pressure modulating baffle 64. The other segment 102 may be disposed next to the blast baffle housing segment. The other segment 102 may partially house and secure the pressure modulating baffle 64. The other segment 102 may include a surface 104 with a screw thread. For instance, radially about the surface 104 female threads may be positioned for threading in the pressure modulation baffle 64.

As shown in FIG. 6, the blast baffle 62 and the pressure modulation baffle 64 may be disposed in the main body 18. Further, the pressure modulation baffle 64 may be positioned concentrically within the blast baffle 62. The pressure modulation baffle may seat against the blast baffle 62. For example, a beveled stopping surface 262 (see e.g., FIG. 10 and FIG. 11) of the blast baffle 62 may provide a seating surface for the pressure modulation baffle 64. Moreover, the stopping surface 264 (see e.g., FIG. 13) of the pressure modulation baffle 64 may seat to the stopping surface 262.

Referring to FIG. 7, the pressure modulation baffle 64 may include an external screw thread 242. For example, male threads on the outermost axial surface 240 of the pressure modulation baffle 64 may be configured and dimensioned to mate with the female screw threads 108 on the other segment 102 (see, e.g., FIG. 9). As shown in FIG. 6, the blast baffle 62 may slide into place within the main body 18, and the pressure modulation baffle 64 may thread into the main body 18 distally at 104. The stopping surface 100 may allow for the pressure modulation baffle 64 to fully seat against the blast baffle 62, which in turn may fully seat against the main body 18 at the seating edge 98. The stopping surface 262 for the pressure modulation baffle 64 may be the interior angle of the cone of the blast baffle 62. Accordingly, the stopping surface 262 of the blast baffle 62 may provide a taper mount for the pressure modulation baffle 64. A taper mount for the pressure modulation baffle 64 may provide a strong and secure connection between the main body 18, the blast baffle 62, and the pressure modulation baffle 64.

Referring to FIGS. 7, 12 and 13, the pressure modulation baffle 62 may include a distal mating surface 230. During assembly, the distal endcap 66 may slide into place and seat against a stopping surface 232. The pressure modulation baffle 64 may include a chamfer 266 such that when the distal endcap 66 is seated against the stopping surface 252, the chamfer 266 exists axially about the forward most outer surface of the distal endcap 66. The juxtaposition of the chamfer 266 and the outermost surface of the distal endcap 66 may form a radial depression for facilitating welding the distal endcap 66 to the pressure modulation baffle 64.

Hence, the void 90 in the main body 18, the blast baffle 62, the pressure modulation baffle 64, and the flash hiding distal end cap 66 may contribute to the modulation efficiency of the muzzle booster 12. The muzzle booster 12 may be specifically designed and configured to provide resonance modulation of ammunition cartridge discharge gases from a firearm. Resonance modulation of ammunition cartridge discharge gases from a firearm may increase back pressure transferred into the operating mechanism of the system. This may affect firearm performance, including by providing greater operational reliability and an increase in the cyclic rate.

Flash Signature Reduction Device

Referring to FIG. 14 and FIG. 15, the exterior and distal end of the distal end cap 66 may include an axial radius 268 cut concentric to the bore 20. This ring cut may be designed to enhance the flash signature reduction. Moreover, external features of a flash hider 22 may be integrated into the distal endcap 66. For example, the distal endcap 66 may include a plurality of distal pointing tines 24. External features of the flash hider 22, including the distal pointing tines, may be designed and configured to maximize flash signature reduction. For instance, the distal pointing tines may be oriented axially about the bore of the flash hider. The distal endcap 66 further may be designed and configured to force exhaust gases to twist when exiting the flash hider. This twisting may transform linear momentum of the exhaust gases into angular momentum. Imparting a non-zero angular momentum to the exhaust gases due to the location, size and shape of the exhaust ports as well as the location and structure of the axially cut ring 268 may contribute to the efficiency of the flash signature reduction of the flash hider.

Quick Connect/Disconnect Fitting and Apparatus

As shown in FIG. 18 and FIG. 19, the spring encapsulator 32 may include a cylindrical body 274 with an inner 278 and outer 276 surface and a central bore. The cylindrical body may include axial depressions 282 that are cut for use with an installation/removal tool. Although the spring encapsulator 1 may include eight circular depressions that are disposed in a ring shaped pattern, other shapes or fittings may be used provided they are compatible with a tool for securely installing the spring encapsulator 32 on—or removing the spring encapsulator from—the main body 18. Additionally, the innermost axial face of the ring-shaped component may include threads 284 for securing the spring encapsulator 32 onto the main body 18. Further, the innermost axial face of the spring encapsulator 32 may include a taper cut 286. The taper cut 286 may form a stopping shoulder. As shown in FIG. 6, the stopping shoulder 286 may abut or promote a secure fit with a proximal area of the main body 18.

Referring to FIG. 16 and FIG. 17, the spring housing 20 may include a tapered mating surface 288, an internal annular surface 150, a counterbore hole 290, and a sleeve. As shown in FIG. 6, the tapered mating surface 288 may cooperate with the main body 18 and the spring encapsulator 32 to capture and enclose the spring 34. Hence, the spring may exist in the space between the main body 18 and the spring housing 30, and thus the sleeve 292 may create a seal protecting the spring 34 from debris.

The spring 34 may be compressed between the spring encapsulator 32 and the annular surface 150 of the spring housing. The compressed spring 34, therefore, may push against the main body 18 to bias the spring housing 50 toward the distal end of the main body 18. In this manner, the spring housing may be spring loaded to shield a locking profile 36 on the distal portion of the main body 18. As described further below, the locking profile 36 may form a receptacle part of a quick connect fitting on the distal end of the main body.

xx

Referring to FIG. 8 and FIG. 20, the muzzle booster 12 may include a locking profile 36. The locking profile 36 may provide attachment sites for connecting and locking an expansion module to the muzzle booster assembly 12. The locking profile 36 may include a number of lug paths 136, though in this embodiment, three lug paths 136 may be radially disposed about the distal end of the main body. As there may be three lug paths 136 in the disclosed embodiment, correspondingly there may be three internal shoulders and three internal stops. Each lug path 136 may permit axial travel of a locking lug (see e.g., FIG. 22) located on the expansion module, as well as provide access to an associated transverse recess 138 and stopping recess 140. The stopping recess 140 may possess a specific radial diameter relative to the locking lug located on the expansion module.

As shown in FIG. 22, an exemplary proximal end cap 298 of an expansion module may include a set of locking lugs 300 that may be maneuvered to releasably interlock with the locking profile 36 on the main body 18. The male locking lugs 300 on the proximal end cap of the expansion module 70 may be positioned opposite a respective lug path 36 on the muzzle booster 12. The male locking lugs 300 may be advanced into the lug paths 36 by pressing the expansion module against the spring housing. As the male locking lugs push the spring housing 30 rearward and compress the spring, the male locking lugs may enter their respective lug paths. Referring to FIG. 23 and FIG. 24, after the male locking lugs 300 are positioned in their respective lug paths 36 beyond the limits of the respective internal shoulder, the locking male lugs may be positioned opposite each respective recess by rotating the expansion module. The shape of the recesses may prevent over rotation of any of the locking lugs 300. The male locking lugs then may translate into their respective recesses, as the spring 34 pushes the spring housing 30 forward. In this configuration, the internal shoulders may block rotational movement of the lugs 300, and the spring housing 30 may block translational movement of the lugs 62. Hence, the spring housing 30 and locking profile 26 may block the lugs 300 from rotating or backing out without intentional physical compression and torque, and thus a selective retention of the lugs 300 in their respective recesses 36 may be provided. Additionally, this attachment mechanism may provide a very fast method of mounting and removing a proximal end cap 298 of an accessory expansion module from the muzzle booster 12.

For example, a quick mount adapter may include a plurality of locking lugs, at least one locking lug being a different size in axial length or radial circumference than remaining lugs, such that the locking lugs are configured and dimensioned to establish one possible mounting orientation only. A quick mount adapter wherein the locking mechanism includes male locking lugs and female locking lugs, the female locking lugs being configured and dimensioned with a diameter that is a specific length wider than the male lugs, effectively fixing the amount of radial movement allowed once the lugs are locked, and thus increasing inherent accuracy of the firearm-muzzle booster (plus firearm suppressor when attached) system. The male locking lugs may be on either the muzzle booster side of the interface (e.g., the muzzle booster side or the expansion module side) and may be interior facing or exterior facing. A quick mount adapter that affixes to a host firearm in such a way that repeatable and reliably circular runout indexing during repeated mounting and unmounting guarantees bore alignment relative to the bore of the host firearm during firing. Although the quick connect/disconnect fitting may include three receptacles, any suitable quick connect/disconnect structure may be used, provided a repeatable and reliable circular runout indexing relative to the bore of the host firearm is maintained during firing, despite repeated mounting and unmounting of the expansion module.

Expansion Modules

An expansion module 72 may be secured to the muzzle booster 12 (see e.g., FIG. 21) by interlocking a set of locking lugs 300 on the proximal end cap 298 (see e.g., FIG. 22, FIG. 23 and FIG. 24) with a complementary locking profile 26 that is disposed on the distal end of the muzzle booster 12. Another expansion module may be secured to the expansion module in a similar manner. Hence, a suppressor may be formed from a muzzle booster 12 and one or more modular expansion modules 72.

Referring to FIG. 25 and FIG. 26, the end cap 298 may form part of an expansion module 72. An expansion module may include an accessory, such as a suppressor. For example, one embodiment of an expansion module may be a suppressor that is configured and dimensioned for use with a specific firearm and ammunition cartridge. Additionally, the expansion module may be configured and dimensioned to receive another expansion module. The other expansion module may include yet another suppressor. A combination of the suppressors may be specifically designed and configured for use with the same firearm and a magnum ammunition cartridge.

FIG. 27 shows an exemplary embodiment 302 of an expansion module 72. The expansion module may include a housing 304 with a quick connection and disconnection fitting 70 at the proximal end. The distal end of the expansion module may include a core 306 with a bore 308, as well as a distal flange 310 with six recesses 312 for receiving a spanner or similar tool. Referring to FIG. 28, the ring and core 306 may form part of a core assembly 314 that is separable from the housing. The core assembly may further include a proximal flange 316 with six vents 318. The outer surface of the distal end cap may include an external screw thread 322. The external screw thread 322 on the distal end cap may be configured and dimensioned to mate with an internal screw thread 324 on the housing. The core 306 may further include a fitting 326 surrounding the bore that can be used to secure the ring to the screw thread on the housing. For example, the fitting may be a hex shaped fitting.

Referring to FIG. 29, the core 306 may include a proximal flange 316, a tubular cylinder 328, four baffles 330 and a distal end cap 332, and a distal flange. The tubular cylinder may include a screw thread on the proximal end, another screw thread on the distal end, and a stop formed by a reduction of the inner diameter of the tubular cylinder. The proximal flange 316 may be annular and further may include an internal screw thread 334 that is configured and dimensioned to mate with the proximal end of the tubular cylinder. Similarly, the distal flange may be annular and may include an internal screw thread 336 that is configured and dimensioned to mate with the external screw thread 338 at the distal end of the tubular cylinder. The baffles may be nested within the tubular cylinder. The leading baffle may include a circumferential surface that is configured and dimensioned to seat on the stop inside the tubular cylinder. The succeeding baffles may then nest against a similarly shaped surface at the distal end of the baffles. The distal end cap may include a complementary shaped proximal end that is configured and dimensioned to nest with the trailing end of the abutting baffle. In this exemplary embodiment, the leading ends of the respective baffles may be uniformly spaced within tubular cylinder.

Referring to FIG. 30, the assembly 314 may be positioned inside the housing 304 and secured by advancing the external threads of the distal flange into the internal screw threads at the open end of the housing. Thus, the housing 304 and core assembly 314 may be combined to form a suppressor including a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12. Generally, the modular suppressor may include a blast chamber bounded by the internal space provided by the proximal cap, the proximal flange, and a portion of the tubular cylinder up to the leading baffle. The annular space 342 between the housing and the tubular cylinder from the proximal flange to the distal flange may form coaxial blast chamber. The respective space bounded by a nested baffle pair may form a pressure modulation chamber 344. Hence, in this embodiment the suppressor may include three pressure modulation chambers. Additionally, the space bounded by the trailing baffle and the distal end cap may form an exit chamber 346.

In an illustrative example, the leading ends of the baffles may the positioned with uniform spacing of approximately 0.544 inches. Further, the leading baffle may be spaced from the proximal bore of the suppressor by approximately 1.46 inches. By contrast, the leading end of the trailing baffle may be spaced from the distal bore of the suppressor by approximately 1.85 inches. Additionally, the inner diameter of the tubular cylinder may be approximately 1.15 inches, the outer diameter of the tubular cylinder may be approximately 1.35 inches, the inner diameter of the housing may be approximately 1.97 inches, and the length of the module suppressor may be approximately 5.2 inches.

Referring to FIG. 31 and FIG. 32, the leading baffle 330 may include an internal surface 348 with a compound curve 350 and an exterior curved surface 352. In this embodiment, the curve ratio of the internal compound curve preferably may range from approximately 0.177 to approximately 0.325. More preferably the curve ratio may range from approximately 0.232 to approximately 0.248. Most preferably, the curve ration may be substantially equal to 0.240. In the illustrative example, the preferred leading curve radius of the internal compound curve may be approximately 0.779 inches and preferred trailing curve radius may be approximately 0.187 inches. Further, the leading inflection point length of the internal compound curve may be approximately 0.412 inches and the trailing inflection point length of the internal compound curve may be approximately 0.552 inches. Also, exterior curve may have a radius of approximately 0.750 inches, the exterior leading inflection point length may be approximately 0.428 inches, and the exterior trailing inflection point may be 0.508 inches. Preferably, the leading aperture diameter (IDLA) and the effective inner aperture diameter (IDIEA) may be substantially equal to 0.400 inches and 1.150 inches, respectively.

Referring to FIG. 33, FIG. 34, and FIG. 35, the distal bore 308 of the suppressor may be situated within a flat annular face 354. The annular face may adjoin a curved surface 356 that transitions to the internal sidewall 358 of the distal end cap 332. In the illustrative example, the diameter of the distal bore of the suppressor may be substantially equal to 0.400 inches and the curve 356 may have a radius R7 of approximately 0.200 inches.

FIG. 36 shows another exemplary embodiment 360 of an expansion module 72. The expansion module may include a quick connection and disconnection fitting 70 at the proximal end. The distal end of the expansion module may include a bore 362, as well as a hexagonal fitting 364. Referring to FIG. 37, the expansion module 360 may be formed from a proximal cap 366, four baffles 368, and a distal end cap 370. Referring to FIG. 38 and FIG. 39, the proximal cap 366, four baffles 368, and a distal end cap 370 may be welded together to form a unitary assembly 372 which may form a suppressor which includes a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12.

Referring to FIG. 38, the modular suppressor 360 may include a blast chamber 374 bounded by the internal space provided by the proximal cap 366 and a portion of the leading baffle 368. The respective space bounded by a nested baffle pair 368 may form a pressure modulation chamber 376. Hence, in this embodiment the suppressor may include three pressure modulation chambers. Additionally, the space bounded by the trailing baffle 368 and the distal end cap 370 may form an exit chamber 378. In this embodiment, the chamber ratio preferably may range approximately 0.85 to 1.15.

In an illustrative example, the leading ends of the baffles 368 may the positioned with uniform spacing of approximately 0.920 inches. Further, the leading baffle may be spaced from the proximal bore of the suppressor by approximately 1.22 inches. By contrast, the leading end of the trailing baffle may be spaced from the distal bore of the suppressor by approximately 1.89 inches. Additionally, the inner diameter of the baffles may be approximately 1.90 inches and the length of the module suppressor may be approximately 6.1 inches. The chamber ratio may be approximately 0.88.

Referring to FIG. 40 and FIG. 41, the proximal cap 366 may include a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12. The bore 380 in the proximal cap may have a diameter D13 which is greater than the diameter of the bore D14 at the distal end. In the illustrative example, the diameter of the bore D13 in the proximal cap may be approximately 0.928 inches.

Referring to FIG. 42 and FIG. 43, the leading baffle 368 may include an internal surface 382 with a compound curve 384 and an exterior surface with a compound curve 386. In this embodiment, the curve ratio of the internal compound curve preferably may range from approximately 0.338 to approximately 0.619. More preferably the curve ratio may range from approximately 0.448 to approximately 0.466. Most preferably, the curve ratio may be substantially equal to 0.457. Further, the curve ratio of the exterior compound curve preferably may range from approximately 0.186 to approximately 0.341. More preferably, the exterior compound curve ratio may range from approximately 0.244 to approximately 0.260. Most preferably, the exterior compound curve ratio may be substantially equal to 0.252.

In the illustrative example, the preferred leading curve radius R8 of the internal compound curve 384 may be approximately 0.820 inches and preferred trailing curve radius R9 may be approximately 0.375 inches. Further, the leading inflection point length of the internal compound curve may be approximately 0.725 inches and the trailing inflection point length of the internal compound curve may be approximately 1.100 inches. Also, the preferred leading curve radius R10 of the exterior compound curve 386 may be approximately 0.770 inches and preferred trailing curve radius R11 of the exterior compound curve may be approximately 0.194 inches. The leading inflection point length of the exterior compound curve may be approximately 0.648 inches and the trailing inflection point length of the exterior compound curve may be approximately 0.475 inches.

Preferably, the leading aperture diameter (IDLA) D15 and the effective inner aperture diameter (IDIEA) D16 may be substantially equal to 0.400 inches and 1.900 inches, respectively.

Referring to FIG. 44, FIG. 45, and FIG. 46, the distal bore 388 of the suppressor may be situated within a flat annular face 390. The annular face may adjoin a curved surface 392 that transitions to the internal sidewall 394 of the distal end cap 370. In the illustrative example, the diameter D14 of the distal bore of the suppressor may be substantially equal to 0.400 inches and the curve may have a radius R12 of approximately 0.200 inches.

FIG. 47 shows another exemplary embodiment 396 of an expansion module 72. The expansion module may include a quick connection and disconnection fitting 70 at the proximal end. The distal end of the expansion module may include a bore 398, as well as a hexagonal fitting 400. Referring to FIG. 48, the expansion module 72 may be formed from a proximal cap 402, four baffles 404, and a distal end cap 406. Referring to FIG. 49, the proximal cap 402, four baffles 404, and a distal end cap 406 may be welded together to form a unitary assembly 408 which may form a suppressor which includes a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12.

The modular suppressor 396 may include a blast chamber 412 bounded by the internal space provided by the proximal cap 402 and a portion of the leading baffle 404. The respective space bounded by a nested baffle pair 404 may form a pressure modulation chamber 414. Hence, in this embodiment the suppressor may include three pressure modulation chambers. Additionally, the space bounded by the trailing baffle 404 and the distal end cap 406 may form an exit chamber 416. In this embodiment, preferably the chamber ratio may range approximately 0.85 to 1.15.

In an illustrative example, the leading ends of the baffles may the positioned with uniform spacing of approximately 0.920 inches. Further, the leading baffle may be spaced from the proximal bore of the suppressor by approximately 1.22 inches. By contrast, the leading end of the trailing baffle may be spaced from the distal bore of the suppressor by approximately 1.89 inches. Additionally, the inner diameter of the baffles may be approximately 2.12 inches and the length of the module suppressor may be approximately 6.1 inches. The chamber ratio may be approximately 0.83.

Referring to FIG. 50 and FIG. 51, the proximal cap 402 may include a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12. The bore 418 in the proximal cap may have a diameter D17 which is greater than the diameter D18 of the bore at the distal end. In the illustrative example, the diameter of the bore D17 in the proximal cap may be approximately 0.928 inches.

Referring to FIG. 52 and FIG. 53, the leading baffle 404 may include an internal surface 420 with a compound curve 422 and an exterior surface with a compound curve 424. In this embodiment, preferably the curve ratio of the internal compound curve may range from approximately 0.338 to approximately 0.619. More preferably the curve ratio may range from approximately 0.448 to approximately 0.466. Most preferably, the curve ratio may be substantially equal to 0.457. Further, the curve ratio of the exterior compound curve preferably may range from approximately 0.199 to approximately 0.364. More preferably, the exterior compound curve ratio may range from approximately 0.261 to approximately 0.277. Most preferably, the exterior compound curve ratio may be substantially equal to 0.269.

In the illustrative example, the preferred leading curve radius R13 of the internal compound curve 422 may be approximately 0.820 inches and preferred trailing curve radius R14 may be approximately 0.375 inches. Further, the leading inflection point length of the internal compound curve may be approximately 0.725 inches and the trailing inflection point length of the internal compound curve may be approximately 1.100 inches. Also, the preferred leading curve radius R15 of the exterior compound curve may be approximately 0.770 inches and preferred trailing curve radius R16 may of the exterior compound curve may be approximately 0.207 inches. The leading inflection point length of the exterior compound curve may be approximately 0.674 inches and the trailing inflection point length of the exterior compound curve may be approximately 0.475 inches.

Preferably, the leading aperture diameter (IDLA) D19 and the effective inner aperture diameter (IDIEA) D20 may be substantially equal to 0.400 inches and 2.120 inches, respectively.

Referring to FIG. 54, FIG. 55, and FIG. 56, the distal bore 398 of the suppressor may be situated within a flat annular face 426. The annular face 426 may adjoin a curved surface 428 that transitions to the internal sidewall 430 of the distal end cap 406. In the illustrative example, the diameter D18 of the distal bore 398 of the suppressor may be substantially equal to 0.400 inches and the curve may have a radius R17 of approximately 0.200 inches.

FIG. 57 shows an yet another exemplary embodiment 432 of an expansion module 72. The expansion module may include a housing 434 with a quick connection and disconnection fitting 70 at the proximal end. The distal end of the expansion module 432 may include a core 436 with a bore 438, as well as a distal flange 440 with six recesses 442 for receiving a spanner or similar tool. Referring to FIG. 58, the distal flange 440 and core 436 may form part of a core assembly 444 that is separable from the housing 434. The core assembly may further include a proximal flange with six vents 448. In one embodiment, the outer surface 450 of the distal end cap may include an external screw thread 452, and the inner surface 454 of the housing at the distal end may include a mating screw thread 456. The distal end cap 436 may be configured and dimensioned to be welded to the housing. The core may further include a fitting 458 surrounding the bore 438 that can be used as a flash hider and to manipulate the core within the housing. For example, the fitting may be a hex shaped fitting.

Referring to FIG. 59, the core 436 may include a proximal flange 446, five baffles 460, 462 and a distal end cap 464 which includes an integral flange 440. The leading baffle 460 may include a screw thread on the external surface. The proximal flange 460 may be annular and further may include an internal screw thread that is configured and dimensioned to mate with the screw thread on the external surface of the leading baffle. Similarly, the flange 440 on the distal end cap may an external screw thread 452 which may be configured and dimensioned to mate with an internal screw thread adjacent to the distal end of the housing. The succeeding baffles 462 may then nest against a similarly shaped surface at the distal end of the baffles. The distal end cap 464 may include a complementary shaped proximal end that is configured and dimensioned to nest with the trailing end of the abutting baffle. In this exemplary embodiment, the leading end of the second baffle is spaced from the leading end of the leading baffle by a first distance and the leading ends of the subsequent respective baffle pairs may be uniformly spaced by a second distance. Generally, the first distance may be less than the first distance.

Referring to FIG. 60, the assembly 440 may be positioned inside the housing 434 and secured by advancing the external threads of the distal flange into the internal screw threads at the open end of the housing. Also, the distal flange 440 may be welded to the housing. Thus, the housing and core assembly may be combined to form a suppressor including a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12. Generally, the modular suppressor may include a blast chamber 466 bounded by the internal space provided by the proximal cap, the proximal flange, and a portion of the leading baffle. The annular space between the housing and the core assembly from the proximal flange to the distal flange may form coaxial blast chamber 468. The respective space bounded by a nested baffle pair may form a pressure modulation chamber. Hence, in this embodiment the suppressor may include five pressure modulation chambers. Additionally, the space bounded by the trailing baffle and the distal end cap may form an exit chamber 480.

In an illustrative example, the leading end of the second baffle may be spaced from the leading end of the leading baffle by approximately 0.594 inches and the leading ends of the subsequent respective baffle pairs may be uniformly spaced by approximately 0.647 inches. Further, the leading baffle may be spaced from the proximal bore of the suppressor by approximately 1.33 inches. By contrast, the leading end of the trailing baffle may be spaced from the distal bore of the suppressor by approximately 1.85 inches. Additionally, the inner diameter of the baffles may be approximately 1.34 inches, the outer diameter of the core assembly may be approximately 1.44 inches, the inner diameter of the housing may be approximately 1.97 inches, and the length of the module suppressor may be approximately 6.2 inches.

Referring to FIG. 61 and FIG. 62, the leading baffle 460 may include an internal surface 482 with a compound curve 484 and an exterior curved surface 486. In this embodiment, the curve ratio of the internal compound curve preferably may range from approximately 0.458 to approximately 0.838. More preferably the curve ratio may range from approximately 0.614 to approximately 0.624. Most preferably, the curve ration may be substantially equal to 0.619. In the illustrative example, the preferred leading curve radius R18 of the internal compound curve may be approximately 1.696 inches and preferred trailing curve radius R19 may be approximately 1.050 inches. Further, the leading inflection point length of the internal compound curve may be approximately 0.388 inches and the trailing inflection point length of the internal compound curve may be approximately 0.784 inches. Also, the exterior curve may have a radius R20 of approximately 1.650 inches, the exterior leading inflection point length may be approximately 0.602 inches, and the exterior trailing inflection point may be 0.602 inches. Preferably, the leading aperture diameter (IDLA) D21 and the effective inner aperture diameter (IDIEA) D22 may be substantially equal to 0.400 inches and 1.340 inches, respectively.

Referring to FIG. 63 and FIG. 64, each of the trailing baffles 470 may include an internal surface 488 with a compound curve 490 and an exterior curved surface 492. In this embodiment, the curve ratio of the internal compound curve preferably may range from approximately 0.177 to approximately 0.324. More preferably the curve ratio may range from approximately 0.232 to approximately 0.248. Most preferably, the curve ration may be substantially equal to 0.240. In the illustrative example, the preferred leading curve radius R21 of the internal compound curve may be approximately 0.780 inches and preferred trailing curve radius R22 may be approximately 0.187 inches. Further, the leading inflection point length of the internal compound curve may be approximately 0.564 inches and the trailing inflection point length of the internal compound curve may be approximately 0.704 inches. Also, the exterior curve may have a radius R23 of approximately 0.750 inches, the exterior leading inflection point length may be approximately 0.577 inches, and the exterior trailing inflection point may be 0.650 inches. Preferably, the leading aperture diameter (IDLA) D23 and the effective inner aperture diameter (IDIEA) D24 may be substantially equal to 0.400 inches and 1.340 inches, respectively.

Referring to FIG. 65, FIG. 66, and FIG. 67, the distal bore of 438 the suppressor may be situated within a flat annular face 494. The annular face may adjoin a curved surface 496 that transitions to the internal sidewall 498 of the distal end cap. In the illustrative example, the diameter D25 of the distal bore 438 of the suppressor may be substantially equal to 0.400 inches and the curve may have a radius R24 of approximately 0.200 inches.

FIG. 68 shows an yet another exemplary embodiment 500 of an expansion module 72. The expansion module 72 may include a housing 502 with a quick connection and disconnection fitting 70 at the proximal end. The distal end of the expansion module may include a core 504 with a bore 506 and a fitting 508.

Referring to FIG. 69, the core 504 generally may be a unitary structure (or a monocore structure) that is separable from the housing 502. The monocore structure may include five baffles 520, one quarter baffle 522, a distal cap 524, a bore 506 in the distal cap. The outer surface of the distal end cap may include an external screw thread 526, and the inner surface of the housing at the distal end may include a mating screw thread 528. The distal cap 524 may be configured and dimensioned to be welded to the housing. The core may further include a fitting 508 surrounding the distal bore 506 that can be used as a flash hider and to manipulate the core within the housing. For instance, the fitting 508 may be externally hex shaped. By contrast, the inner surface 528 of the fitting may have circular shape, which further may include a screw thread. The screw thread may be configured and dimensioned to mate with a screw thread on an accessory. For example, without limitation, the accessory may be a flash hider or a compensator with a mating screw thread that may be advanced into the screw thread on the inner surface of the fitting.

Referring to FIG. 70, the core 504 may be positioned inside the housing 502 and secured by advancing the external threads 526 of the distal flange 524 into the internal screw threads 528 at the open end of the housing. Also, the distal flange may be welded to the housing. Thus, the housing and core assembly may be combined to form a suppressor including a quick connection and disconnection fitting 70 at the proximal end. The quick connection and disconnection fitting 70 may be configured and dimensioned to mate with the locking profile 26 of the muzzle booster 12. Generally, the modular suppressor may include a blast chamber 530 bounded by the internal space provided by the proximal cap, the proximal flange, and a portion of the leading baffle. The respective space bounded by a nested baffle pair may form a pressure modulation chamber 532. Hence, in this embodiment the suppressor may include four pressure modulation chambers. Additionally, the space bounded by the trailing baffle and the distal end cap may form an exit chamber 534. The exit chamber may include a quarter baffle.

In an illustrative example, generally the leading ends of respective baffle pairs may be uniformly spaced by approximately 1.125 inches. The last baffle and the quarter baffle have different spacing. As shown in FIG. 74, the spacing between the leading end of the last baffle and the leading end of the quarter baffle may be approximately 1.075 inches. The spacing between the leading end of the quarter baffle and the distal bore may be approximately 0.55 inches. Referring to FIG. 70, the leading baffle may be spaced from the proximal bore of the suppressor by approximately 0.58 inches. Additionally, the maximum inner dimension of the baffles may be approximately 1.76 inches, the inner diameter of the housing may be approximately 1.97 inches, and the length of the module suppressor may be approximately 7.2 inches. Referring to FIG. 73, the leading aperture diameter (IDLA) and the distal bore 506 may be substantially equal to 0.385 inches. Also, the outer diameter of the monocore structure may be approximately 1.96 inches. Referring to FIG. 74, The leading end of the trailing baffle may be spaced from the bore of the quarter baffle by approximately 1.075 inches.

Although, the monocore structure 504 may be a unitary structure as shown in shown in FIGS. 71, 72, 75 and 76, the monocore 504 may be formed from multiple parts or combined with other parts. In this embodiment, however, the chamber ratio preferably may range approximately 0.85 to 1.15. In the illustrative example, however, the chamber ratio may be approximately 0.71.

In use, the muzzle booster may increase efficiency of a host firearm that is chambered for a specific ammunition cartridge by regulating discharge gases from the ammunition cartridge. More particularly, the muzzle booster assembly may modulate a pressure wave and the resonance of the pressure wave from the ammunition cartridge discharge gases. Modulation of the pressure wave and the resonance of the pressure wave may provide performance benefits by increasing the minimum amount of overall back pressure to the operating mechanism of the firearm. This may enhance reliability of the cycle of operation, as well as an increase the cyclic rate of the host firearm. For instance, the muzzle booster may be used with an autoloading firearm chambered for 300 Blackout with a 5.5″ barrel firing 220 grain ammunition. Additionally, the distal end of the muzzle booster may be configured and dimensioned to receive an expansion module. The expansion module may be selectively and removably connected to the muzzle booster to further affect the firearm's operational performance. For example, the expansion module may include a suppressor.

For example, the muzzle booster may be used to a part of a method of regulating ammunition cartridge discharge gases from a firearm. The method may include providing a muzzle booster which includes a proximal end, a distal end, and an orifice extending from the proximal end to the distal end; fixing a pair of baffles in the orifice; applying a pressure wave of ammunition cartridge discharge gases to the pair of baffles; and modulating the pressure wave of ammunition discharge gases across a pair of baffles; and expelling a standing wave of ammunition cartridge discharge gases from the orifice, the standing wave forming a poloidal flow pattern. In another example, the muzzle booster may be used to affect operational performance of a firearm. The method may include providing a muzzle booster; providing an autoloading firearm; securing the muzzle booster to the autoloading firearm; passing a pressure wave of ammunition cartridge discharge gases from the autoloading firearm through the muzzle booster; and modulating the pressure wave and resonance of the pressure wave to increase cyclic rate of the autoloading firearm. Moreover, the method may include increasing sound signature reduction efficiency of the autoloading firearm by transforming linear momentum of the pressure wave into angular momentum. Additionally, the method may include providing a modular suppressor and removably connecting the modular suppressor to the muzzle booster. Further still the method may include expelling a standing wave of ammunition cartridge discharge gases from the modular suppressor.

While it has been illustrated and described what at present are considered to be preferred embodiments of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. For example, although the exemplary embodiment of the muzzle booster assembly disclosed herein may utilize resonance modulation of discharge gases to enhance operational performance of a firearm, resonance modulation in accordance with the present invention may be incorporated into various weapon accessories including, without limitation, suppressors, silencers, sound moderators and other devices and equipment. Moreover, features and or elements from any embodiment may be used singly or in combination with other embodiments. Therefore, it is intended that this invention not be limited to the particular embodiments disclosed herein, but that the invention include all embodiments falling within the scope and the spirit of the present disclosure. 

1-9. (canceled)
 10. A muzzle booster for regulating firearm discharge gases comprising: a main body including a proximal end and a distal end, the main body comprising: an orifice extending from the proximal end to the distal end, the orifice comprising an inner surface; a first baffle positioned in the orifice, the first baffle including a first central axis and a first cross section through the first central axis, the first baffle comprising a first leading end, a first trailing end spaced from the first leading end along the first central axis, a first passage extending from the first leading end to the first trailing end, the first passage being bound by a first interior surface, the first cross section comprising a first interior compound curve adjacent to the first leading end, and a first exterior surface extending from the first leading end to the first trailing end, the first exterior surface comprising a first exterior compound curve proximate to the first leading end, the first exterior compound curve being convex with respect to the first central axis, a second baffle arranged in the first trailing end, the second baffle comprising a second central axis and a second cross section through the second central axis, the second baffle comprising a second leading end, a second trailing end spaced from the second leading end along the second central axis, a second passage extending from the second leading end to the second trailing end, the second passage being bound by a second interior surface, the second cross section comprising a second leading linear segment adjacent to the second leading end, the second leading linear segment being disposed at an acute angle with respect to the second central axis.
 11. The muzzle booster of claim 10, wherein the first interior compound curve comprises: a first leading curve comprising a first leading curve radius, the first leading curve being convex with respect to the first central axis, and a first trailing curve comprising a first trailing curve radius, the first trailing curve being concave with respect to the central axis.
 12. The muzzle booster of claim 11, wherein the first interior compound curve defines a first curve ratio of about 0.190 to about 0.349, and the first exterior compound curve defines a first exterior curve ratio of about 0.093 to about 0.102.
 13. The muzzle booster of claim 10, wherein the inner surface of the orifice comprises a central axis and a cross section through the central axis, the cross section comprising: a first segment abutting the proximal end, the first segment comprising a first side wall, the first sidewall bounding a first volume and defining a first inner diameter perpendicular to the central axis, a second segment proximate the first segment, the second segment comprising a second side wall bounding a second volume and defining a second inner diameter perpendicular to the central axis, the second inner diameter being greater than the first inner diameter, a third segment proximate the second segment, the third segment comprising a third side wall bounding a third volume and defining a third inner diameter perpendicular to the central axis, the third inner diameter being greater than the second inner diameter.
 14. The muzzle booster of claim 13, wherein the third segment further comprises a first transverse surface abutting the third side wall and the second side wall, the first transverse surface forming a first seat for the first baffle.
 15. The muzzle booster of claim 14, wherein the inner surface of the orifice further comprises: a fourth segment proximate the third segment, the fourth segment comprising a fourth side wall bounding a fourth volume and defining a fourth inner diameter perpendicular to the central axis, the fourth inner diameter being greater than the third inner diameter, the fourth side wall comprising a first screw thread, and the second baffle further comprises a second exterior surface extending from the second leading end to the second trailing end, the second exterior surface comprising a second screw thread, the second screw thread being configured and dimensioned to mate with the first screw thread for securing the second baffle to the main body.
 16. The muzzle booster of claim 15, wherein the muzzle booster further comprises a distal end cap, and the distal end cap comprises a discharge port.
 17. The muzzle booster of claim 16, wherein the second sidewall and the first baffle bound a first chamber, the first chamber comprising a first chamber volume, and the second interior surface and the distal end cap bound a second chamber, the second chamber comprising a second chamber volume, the second chamber volume divided by the first chamber volume defining a chamber ratio, the chamber ratio being between 0.850 and 1.150.
 18. The muzzle booster of claim 16, wherein the distal end cap further comprises a flash signature reduction device adjacent to the discharge port.
 19. An apparatus for regulating firearm discharge gases comprising: the muzzle booster of claim 10; and an expansion module abutting the main body.
 20. The apparatus of claim 19, wherein the expansion module comprises a blast chamber comprising a blast chamber volume, an exit chamber comprising an exit chamber volume, and a plurality of baffles disposed between the blast chamber and the exit chamber.
 21. The apparatus of claim 20, wherein the plurality of baffles are four baffles.
 22. The apparatus of claim 20, wherein each of the plurality of baffles are a part of a unitary structure.
 23. The apparatus of claim 20, wherein at least one of the plurality of baffles comprises a leading end and an interior compound curve adjacent to the leading end, the interior compound curve defining a curve ratio of about 0.232 to about 0.248.
 24. The apparatus of claim 20, wherein at least one of the plurality of baffles comprises a leading end and an interior compound curve adjacent to the leading end, the interior compound curve defining a curve ratio of about 0.448 to about 0.466.
 25. The apparatus of claim 20, wherein at least one of the plurality of baffles comprises a leading end and an interior compound curve adjacent to the leading end, the interior compound curve defining a curve ratio of about 0.614 to about 0.624.
 26. The apparatus of claim 20, wherein the exit chamber volume divided by the blast chamber volume defines a second chamber ratio, the second chamber ratio being between 0.850 and 1.150
 27. The apparatus of claim 20, further comprising a coaxial blast chamber disposed around the plurality of baffles, the coaxial blast chamber being in fluid communication with the blast chamber. 